This equipment serves as the core terminal station within a flat-wire stator production line. Its function is to weld the hairpin ends—specifically the twisted tips—of the flat wires into robust electrical connection terminals.
The equipment offers a choice between two welding processes: TIG welding or laser welding. For TIG welding, the single-point cycle time is 2 seconds, with a pull-out force of ≥500 N.
Laser welding utilizes a 6 kW power source (configured as 4+2 or 2+4), featuring deep-penetration welding capabilities. It is particularly well-suited for welding 'mini-pin' terminals (≤4 mm), achieving a pull-out force of ≥300 N.
The equipment integrates a comprehensive suite of functions, including rapid positioning via a SCARA robot, a water-cooling unit, a fume extraction and purification system, MES data monitoring, and 'one-touch' recipe recall for rapid model changeovers.
Suitable for welding the copper end faces of flat-wire stators used in the drive motors of new energy vehicles, specifically following the wire-twisting process.
TIG welding is suitable for standard flat-wire terminals, while laser welding is suitable for both standard terminals and fine 'mini-pin' terminals.
Within the production line, this station is positioned downstream of the wire-twisting machine and upstream of the electrical performance testing station.
The equipment is compatible with stators featuring an outer diameter of 100–500 mm, flat-wire widths of 2–6 mm, and 'mini-pin' dimensions of ≤4 mm.
Key Functions
Automatically clamps and positions the stator; a SCARA robot rapidly maneuvers the welding torch or laser head to each specific welding point.
Real-time monitoring of welding process parameters.
Integrated water-cooling unit ensures thermal stability.
Fume extraction and purification system captures welding fumes and dust.
Optional visual inspection system for weld points.
MES interface for data uploading.
'One-touch' recipe recall to facilitate rapid model changeovers.
Core Features (General)
1. High Speed & Throughput: TIG welding ≤2 seconds/point; Laser welding ≤1.5 seconds/point.
2. Rapid Robotic Positioning: SCARA robot enables fast and precise positioning across multiple welding points.
3. Comprehensive Auxiliary Systems: Includes both a water-cooling unit and a fume extraction/purification system.
4. Intelligent Model Changeover: 'One-touch' recipe recall allows for model changeovers in ≤5 minutes.
5. Data Traceability: TIG welding supports MES monitoring; Laser welding offers optional power monitoring capabilities.
TIG Welding Features
High weld strength; pull-out force ≥ 500 N;
Full, robust weld spots; suitable for thicker flat wires and high-stress operating conditions.
Laser Welding Features
Standard configuration: 4 + 2 kW (6 kW total); Upgraded configuration: 2 + 4 kW (6 kW total), enabling deep-penetration welding;
Significant advantages for mini-pins (≤ 4 mm); pull-out force ≥ 300 N after deep-penetration welding;
Smooth weld spots with a small heat-affected zone (HAZ).
Equipment Dimensions (L × W × H): 3.5 m × 2.2 m × 2.2 m (Typical)
TIG Welding Cycle Time (Per Point): ≤ 2.0 s
Laser Welding Cycle Time (Per Point): ≤ 0.3 s
TIG Welding Pull-out Force: ≥ 500 N
Laser Welding Deep-Penetration Pull-out Force (Mini-pin): ≥ 300 N
Total Laser Power: 6 kW (4+2 or 2+4 configuration)
Deep-Penetration Welding Capability: Supported; suitable for mini-pins (≤ 4 mm)
Robot Type: SCARA Robot; rapid positioning
Auxiliary Systems: Water Chiller + Dust Extraction & Purification System
Compatible Stator Outer Diameter: 100 ~ 500 mm
Compatible Flat Wire Dimensions: Width: 2–6 mm; Thickness: 1–3 mm; Mini-pin: ≤ 4 mm
Model Changeover Method: One-touch recipe recall; changeover time ≤ 5 minutes
MES Monitoring: Available for TIG welding; Optional for Laser welding
Power Supply: 380 V / 50 Hz
Air Supply: 0.5 ~ 0.7 MPa
Equipment Weight: TIG Welding: Approx. 4.5 tons / Laser Welding: Approx. 5.0 tons
Safety Standards: CE Certified
